US10020149B2 - Control apparatus for controlling a switching element - Google Patents

Control apparatus for controlling a switching element Download PDF

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Publication number
US10020149B2
US10020149B2 US15/248,456 US201615248456A US10020149B2 US 10020149 B2 US10020149 B2 US 10020149B2 US 201615248456 A US201615248456 A US 201615248456A US 10020149 B2 US10020149 B2 US 10020149B2
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Prior art keywords
switching element
control apparatus
accordance
load stage
switching
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US15/248,456
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US20170076891A1 (en
Inventor
Franz Dold
Jonas WEIDENMULLER
Stephan HENNEBERGER
Frederik BEHRE
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Sick AG
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Sick AG
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Program-control systems
    • G05B19/02Program-control systems electric
    • G05B19/04Program control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042Program control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G05B19/0423Input/output
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H47/00Circuit arrangements not adapted to a particular application of the relay and designed to obtain desired operating characteristics or to provide energising current
    • H01H47/002Monitoring or fail-safe circuits
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/20Pc systems
    • G05B2219/21Pc I-O input output
    • G05B2219/21108Module, I-O module consisting of counters and comparators
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H71/00Details of the protective switches or relays covered by groups H01H73/00 - H01H83/00
    • H01H71/04Means for indicating condition of the switching device
    • H01H2071/044Monitoring, detection or measuring systems to establish the end of life of the switching device, can also contain other on-line monitoring systems, e.g. for detecting mechanical failures

Definitions

  • the invention relates to a control apparatus for controlling a switching element, preferably a mechanical relay, in accordance with claim 1 .
  • switching elements such as mechanical relays are used in a number of applications to control electrical devices connected via the switching elements.
  • the switching elements which are preferably mechanical, in this respect have a limited number of possible switching cycles which are comparatively low in comparison with non-mechanical switches such as transistors.
  • the switching elements are as a rule the weakest element in the grouping of a switching device, the expected service life under the given loads is of particular interest to plan servicing cycles for a plant or to make a statement on the duration of an error-free operation.
  • Such a possibility would also be of interest for simple switching devices such as relay modules which do not have any link to an intelligent logic such as a higher-ranking programmable logic controller PLC, whereby this function could be outsourced.
  • the known (safety) relay modules recognize a failure of the relay such as contact welding and block the restart.
  • the relay module subsequently has to be replaced.
  • the user's attention is not drawn to an (imminent) reaching of the expected switching cycles by the device. He is only informed of the failure. Alternatively, he has to take his own precautions.
  • a control apparatus for controlling a switching element, preferably a mechanical relay, having an operating unit for setting a load stage at which the switching element can be operated, having a control unit for calculating a first numerical value which reflects expected switching cycles of the switching element estimated on the basis of the set load stage (BS) and which corresponds to an expected service life of the switching element in dependence on the set load stage (BS), and for determining a second numerical value which reflects effected switching cycles of the switching element, with information being able to be drawn on by a user from a difference between the first and second numerical values or from a quotient from the second numerical value to the first numerical value during operation of the switching element.
  • BS set load stage
  • BS set load stage
  • the switching cycles of the switching element calculated and expected in dependence on the set load stage in the sense of the information in particular reflect a possible maximum total number of switching cycles of the switching element under the set load stage, with the effected switching cycles reflected by the second number not being included therein.
  • the operating unit is formed from a key, a key pad or a rotary switch.
  • the load stage can be calculated from a load current, a load voltage, a load type and/or an expected switching frequency in a provided application of the switching element.
  • the load stage to be set can be determined from numerical parameter values which can be drawn on by the user from a diagram and/or from an application-specific query in a data sheet.
  • the diagram advantageously comprises a current/voltage diagram with marked degrees of wear to which the switching element is exposed. The advantage thereby results that the user can see the load stage of the switching element to be set in a very simple manner in accordance with the degree of wear of the switching element in the application and can set it in the control apparatus.
  • the application-specific query queries an inductive load or an occurrence rate of a specific switching frequency by which the load stage for the switching element can be determined.
  • the load stage is numerically divided into a range, preferably from zero to six, with the load stage having a number which is as small as possible, in particular zero, corresponding to a highest possible number of switching cycles and with the load stage having a number which is as large as possible, in particular six, corresponding to a lowest number of switching cycles.
  • the information on the difference between the first and second numerical values reflects a still remaining residual service life of the switching element.
  • the information on the quotient from the second numerical value to the first numerical value reflects a percentage ratio between the already effected switching cycles and the expected switching cycles of the switching element.
  • a diagnosis mode can be selected by means of the operating unit in which the still remaining residual service life of the switching element can be displayed without any interruption of the operation of the switching element.
  • a display unit which displays the set load stage and the effected switching cycles.
  • the display unit advantageously displays information on the difference between the first numerical value and the second numerical value, in particular on the still remaining residual service life of the switching element.
  • the display unit advantageously displays the information on the quotient from the second numerical value to the first numerical value, in particular the percentage ratio between the already effected switching cycles and the expected maximum possible switching cycles.
  • control apparatus in accordance with the invention can be designed in a similar manner by further features and shows similar advantages in this respect. Such further features are described by way of example, but not exclusively, in the dependent claims following the independent claims.
  • FIG. 1 a schematic representation of a control apparatus in accordance with the invention
  • FIGS. 2 a -2 c a schematic, exemplary representation of a determination in accordance with the invention of a load stage of the switching element
  • FIGS. 3 a -3 b a schematic, exemplary representation of a display at the control apparatus in accordance with the invention.
  • FIG. 1 A schematic setup of a control apparatus 1 in accordance with the invention for controlling a switching element, in the form of a mechanical relay module, is shown in FIG. 1 to which an actuator A is connected by way of example, wherein the relay module 1 is supplied with input signals via an input line IN to switch the actuator A on or off via n output line OUT or to activate or deactivate a load circuit.
  • the preferred relay module 1 shown has an operating unit 2 which is provided for setting a load stage BS for the relay module 1 .
  • the load stage BS represents a load with which the relay module 1 is operated or loaded in its operation. I.e. the load of the relay module 1 depends inter alia on which kind of actuators A is connected to the relay module 1 , on how high a load current or a load voltage is switched onto the relay module 1 or on how frequently the relay module 1 has to be switched.
  • the operating unit 2 is formed in a preferred manner from a key, a key pad or a rotary switch so that a user can set the load stage BS at the relay module 1 in a very simple manner.
  • the operating unit 2 preferably comprises a rotary switch 2 at which the load stages BS are displayed such that the user can carry out the setting at the control apparatus 1 simply by rotating the indicator to the respective load stage BS after the determination of the correct load stage BS of the shown application for the control apparatus 1 in accordance with the invention.
  • the set load stage BS for the relay module 1 is advantageously likewise stored in the non-volatile memory.
  • the control unit CPU calculates a first numerical value Z 1 for expected switching cycles of the switching element at the set load stage BS on the basis of the set load stage BS, wherein the first numerical value Z 1 corresponds to an expected service life, in particular to a maximum service life, of the switching element in dependence on the set load stage BS.
  • a control unit CPU determines a second numerical value Z 2 which reflects effected switching cycles of the switching element.
  • the effected switching cycles can be counted by the control unit CPU and can be stored in a non-volatile memory which belongs to the control unit CPU of the control apparatus in accordance with the invention or of the relay module 1 .
  • the control unit CPU forms a difference from the first and second numerical values Z 1 and Z 2 or a quotient Z 2 /Z 1 from the second numerical value to the first numerical value Z 2 and Z 1 .
  • Information from the difference between the first and second numerical values Z 1 and Z 2 or from the quotients Z 2 /Z 1 from the second numerical value to the first numerical value Z 2 and Z 1 can be drawn on by the user during an operation of the switching element.
  • the information on the difference between the first and second numerical values Z 1 and Z 2 reflects a still remaining residual service life of the switching element which results from a comparison between the expected switching cycles or the expected service life of the switching element and the already effected switching cycles or the wear of the switching element.
  • the information on the quotient Z 2 /Z 1 from the second to the first numerical values Z 2 and Z 1 in turn reflects a percentage ratio between the already effected switching cycles or the wear of the switching element to the expected switching cycles of the switching element or of the maximum possible service life of the switching element.
  • FIGS. 2 a to 2 c A schematic, exemplary representation of a determination in accordance with the invention of the load stage BS of the switching element which can be set in the control apparatus 1 is shown in FIGS. 2 a to 2 c .
  • the load stage BS can be calculated from a load current, a load voltage, a load type and/or an expected switching frequency in a provided application of the switching element.
  • the load stage BS to be set can be determined from numerical parameter values Pzw 1 to Pzw 4 which can be drawn on by the user from a diagram and/or from an application-specific query in a data sheet.
  • control apparatus 1 After the determination of the load stage BS to be set, the control apparatus 1 can be set as described above and the switching element can be operated in accordance with the provided use.
  • the shown diagram in FIG. 2 a comprises a current/voltage diagram with marked degrees of wear of the switching element.
  • the X axis of the diagram represents a permanent current in amperes with which the relay module 1 is loaded.
  • the Y axis of the diagram represents the switching voltage in volts with which the relay module 1 is switched.
  • the area in the dashed rectangle of the switching voltage axis and of the permanent current axis is thus the degree of wear the switching element is exposed to. This degree of wear is divided by way of example into +1 to +4. I.e. the greater the switching voltage and the permanent current are, the greater the degree of wear is which acts on the switching element or the higher the load stage BS is which is to be set for the control apparatus in accordance with the invention or for the relay module in accordance with the invention.
  • wear of the switching element is the smallest at +1 and the wear of the switching element is correspondingly the largest at +4.
  • the user can see the first numerical parameter value Pzw 1 from the current/voltage diagram.
  • the user can determine further numerical parameter values Pzw 2 to Pzw 4 to be taken into account for the determination of the load stage BS for the use of the control apparatus 1 in accordance with the invention from the exemplary, application-specific queries shown in FIG. 2 b.
  • the queries can be stored in a data sheet of the control apparatus 1 in accordance with the invention so that the user can read off the matching numerical parameter value Pzw 2 to Pzw 4 or it can be displayed at the control apparatus 1 in accordance with the invention so that the user can input the matching numerical parameter value Pzw 2 to Pw 4 by means of the operating unit 2 .
  • the control apparatus 1 in accordance with the invention has a display unit 3 which displays the application-specific queries to the user so that the user can input the correct numerical parameter value Pzw 2 to Pzw 4 with respect to the respective application-specific query by means of the operating unit 2 to obtain the correct load stage BS.
  • the display unit 3 advantageously shows the set load stage BS, the maximum possible switching cycles dependent on the set load stage BS and the effected switching cycles.
  • the display unit 3 in particular also serves to display the information on the difference between the first and second numerical values Z 1 and Z 2 , i.e. the still remaining residual service life of the switching element, or the information on the quotient Z 2 /Z 1 from the second to the first numerical value Z 2 and Z 1 , i.e. the percentage ratio between the wear and the maximum possible service life of the switching element.
  • the user can see the still remaining residual service life of the switching element during the operation of the control apparatus 1 in accordance with the invention or of the relay module without interrupting the operation of the switching element in that the user preferably selects a diagnosis mode and allows the information from the difference between the first and second numerical values Z 1 and Z 2 or, as shown in FIGS. 3 a and 3 b as bars, the information from the quotients Z 2 /Z 1 from the second numerical value to the first numerical value Z 2 and Z 1 to be displayed at the display unit 3 .
  • the user can respond with respect to the load type, namely “Inductive load?” or “Direct current?”.
  • a numerical parameter value Pzw 2 equal to two (Yes: +2) is set and on a Yes response to the query with respect to the direct current, a numerical parameter value Pzw 4 equal to one (Yes: 1) is set.
  • the numerical parameter values Pzw 2 and Pzw 4 are set equal to zero (No: +0).
  • a further application-specific query asks for the number of occurrences of an incidence of a switching frequency at which the control apparatus 1 in accordance with the invention is operated or the switching element is switched. It is determined in this respect whether a switching frequency greater than 0.5 Hz occurs more frequently. On a Yes response to the query with regard to the number of occurrences of the switching frequency greater than 0.5 Hz, a numerical parameter value Pzw 3 equal to one (Yes: +1) is set and on a No response, the numerical parameter value Pzw 3 equal to zero (No: +0) is set.
  • the application-specific query queries an inductive load or the number of occurrences of a specific switching frequency by which the load stage BS for the switching element can be determined.
  • the numerical parameter values Pzw 1 to Pzw 4 determined by the user are summed, from which the load stage BS to be set for the control apparatus 1 in accordance with the invention is determined in the corresponding application.
  • the application-related load stage BS determined in this manner can be set such that the control unit CPU calculates the information relating to the still remaining residual service life of the switching element and can provide it to the user.
  • FIGS. 3 a and 3 b A respective schematic, exemplary representation of the display unit 3 is shown at the control apparatus 1 in accordance with the invention in FIGS. 3 a and 3 b .
  • the already effected switching cycles (“70,150 or “100,150”) and the set load stage BS (“2”) are displayed for the user on the display unit 3 .
  • the load stage BS is preferably numerically divided into a range from 0 to 6.
  • the load stage BS equal to zero (“0”) corresponds to a number of switching cycles which is as high as possible.
  • the load stage BS equal to six (“6”) corresponds to a lowest number of switching cycles.
  • the relay module in accordance with the invention is loaded the least in operation, whereas at the load stage BS equal to six, the relay module in accordance with the invention is loaded the most in operation.
  • the user can see the still remaining residual service life of the switching element using the displayed information from the difference between the effected switching cycles (10,150 or 100,150) of the switching element and the expected switching cycles (135,000) of the switching element dependent on the load stage BS or using the displayed bar of the information on the quotient Z 2 /Z 1 from the effected switching cycles (70,150 or 100,150) to the maximum possible switching cycles (135,000) of the switching element.
  • the information of the display in FIG. 3 a indicates to the user that the relay module is still in a good condition since a consumed service life of the switching element is a little above half the expected (maximum) service life of the switching element at the load stage equal to two. It is advantageous in this respect that the shown bar displays the information from the quotient Z 2 /Z 1 from the second to the first numerical values Z 2 and Z 1 in percent. The user can hereby read off the percentage wear of the switching element with respect to the maximum possible service life of the switching element. The user can, in contrast, see from the information of the display in FIG. 3 b that a wear of the switching element is already significantly high so that a replacement of the switching element should be carried out soon.
  • the user thus obtains an overview on the wear of the switching element in accordance with the invention at any time directly at a machine having the control apparatus 1 in accordance with the invention and can carry out a servicing of the relay module in a time and cost optimized manner.
  • the user acquires the information that, if the switching element has been operated for one year at the load stage BS equal to two (“2”), the switching element can be operated for still almost a further one year at 70,150 switching processes effected up to then since the wear is just a above half the expected maximum possible service life of the switching element.
  • the servicing or the replacement of the switching element can therefore be planned in a time and cost optimized manner.
  • the user can change the load stage BS by means of the operating unit 2 , for example in accordance with a change of the application, so that the control unit CPU can determine the first numerical value Z 1 again which corresponds to the newly set load stage BS.
  • the control unit CPU can determine the first numerical value Z 1 again which corresponds to the newly set load stage BS.
  • the newly obtained information from the difference between the first and second numerical values Z 1 and Z 2 or the information from the quotient Z 2 /Z 1 from the second to the first numerical values Z 2 and Z 1 indicates to the user how high the already consumed service life or the percentage wear of the switching element is while taking account of the newly set load stage BS and, on the other hand, whether a further operation of the relay module is economic under the new load stage BS or whether a replacement should be carried out immediately or in the near future.
  • the result may therefore advantageously arise in the new calculation that the display unit 3 indicates 100% as the information. This means that with the set new load stage BS a failure of the relay module would result in the direct future so that it would be advisable not to operate the already used and thus worn switching element under the newly set load stage BS or in accordance with the new application.
  • the user is given the possibility to avoid a failure of the switching element in operation under the new application in advance in that he replaces the used switching element with a new switching element which is more suitable for the newly set load stage BS of the new application.
  • the display of the information at the display unit 3 can furthermore in particular change faster if the newly set load stage BS is a higher load stage BS.
  • the control apparatus 1 in accordance with the invention displays a large interval between the already consumed service life of the switching element and the newly expected (maximum) service life of the switching element so that a corresponding servicing time can be displaced backward in time.
  • the user hereby obtains a higher planning certainty for the service of the switching element.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Train Traffic Observation, Control, And Security (AREA)
  • Relay Circuits (AREA)
  • Programmable Controllers (AREA)
US15/248,456 2015-09-11 2016-08-26 Control apparatus for controlling a switching element Active 2037-03-16 US10020149B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP15184905.6 2015-09-11
EP15184905.6A EP3142136B1 (de) 2015-09-11 2015-09-11 Steuerungsvorrichtung zum steuern eines schaltelements
EP15184905 2015-09-11

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US10020149B2 true US10020149B2 (en) 2018-07-10

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US10955477B2 (en) 2018-06-29 2021-03-23 Hamilton Sundstrand Corporation Power distribution health management and monitoring
DE102018217336A1 (de) * 2018-10-10 2020-04-16 Siemens Aktiengesellschaft Restlebensdauervorhersage für Schalter
US11362538B2 (en) * 2020-01-31 2022-06-14 Schneider Electric It Corporation Uninterruptible power supply component analysis system and method
FR3155947A1 (fr) * 2023-11-24 2025-05-30 Airbus Operations (S.A.S.) Dispositif de commutation électrique d’un circuit électrique de puissance comportant un système de maintenance prédictive

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WO2005104155A1 (de) 2004-04-21 2005-11-03 Siemens Aktiengesellschaft Verfahren zum ermitteln eines eine abnutzung von schaltkontakten eines leistungsschalters angebenden restschaltspiel-wertes
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WO2005104155A1 (de) 2004-04-21 2005-11-03 Siemens Aktiengesellschaft Verfahren zum ermitteln eines eine abnutzung von schaltkontakten eines leistungsschalters angebenden restschaltspiel-wertes
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EP3142136A1 (de) 2017-03-15
US20170076891A1 (en) 2017-03-16
CN106527251A (zh) 2017-03-22
CN106527251B (zh) 2019-04-12
EP3142136B1 (de) 2018-07-18

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